AUTOBOX (ABX-2L-V2) USER MANUAL

Transcription

1 AUTOBOX (ABX-2L-V2) USER MANUAL PL 602-V2 REV F (12/2017)

2 TABLE OF CONTENTS.MANUFACTURER S INFORMATION... 3 SPECIFICATIONS... 3 DESCRIPTION OF EQUIPMENT AND INTENDED USE... 3 KEY FEATURES... 3 CE DECLARATION OF INCORPORATION... 4 WARNING AND SAFETY INSTRUCTIONS... 5 OPERATOR TRAINING... 5 PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS... 5 SAFETY LABEL DEFINITIONS... 5 PRE-RUN SAFETY CHECK... 6 SYSTEM ASSEMBLY - OVERVIEW... 7 LIGHTWEIGHT POSITIONER - OVERVIEW... 8 LIGHTWEIGHT POSITIONER CLAMP SELECTION... 9 LIGHTWEIGHT POSITIONER SET-UP HOSE GUIDE ASSEMBLY - OVERVIEW HOSE GUIDE ASSEMBLY SET-UP HOSE GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER SET UP AUTOBOX (ABX-2L-V2) HOSE TRACTOR - OVERVIEW AUTOBOX (ABX-2L-V2) HOSE TRACTOR DOORS AND PINS AUTOBOX (ABX-2L-V2) HOSE TRACTOR DRIVE ROLLERS AUTOBOX (ABX-2L-V2) HOSE TRACTOR TO HOSE GUIDE ASSEMBLY CONTROL BOX - OVERVIEW CONTROL BOX SET-UP CONTROL BOX AIR SUPPLY FITTING CONTROL BOX TO AUTOBOX (ABX-2L-V2) HOSE TRACTOR ASSEMBLY OPERATION COLLET INSERTION, HOSE, AND HOSE STOP INSTALLATION CONTROL PANEL FUNCTIONS, TEST RUN, AND RUN PROCEDURES HIGH PRESSURE HOSE AND HOSE CLAMP MAINTENANCE STORAGE, TRANSPORTATION, AND HANDLING PART DIAGRAMS ACCESSORIES OVERVIEW TERMS AND CONDITIONS AND WARRANTY

3 MANUFACTURER S INFORMATION StoneAge Inc. 466 S. Skylane Drive Durango, CO 81303, USA Phone: Toll Free: StoneAge Europe Unit 2, Britannia Business Centre Britannia Way Malvern WR14 1GZ United Kingdom Phone: +44 (0) This manual must be used in accordance with all applicable national laws. The manual shall be regarded as a part of the machine and shall be kept for reference until the final dismantling of the machine, as defined by applicable national law(s). SPECIFICATIONS AUTOBOX (ABX-2L-V2) Hose Tractor Weight: AUTOBOX (ABX-2L-V2) Hose Tractor Size: Maximum Feed Rate: Minimum Feed Rate: Maximum Push/Pull Force: Minimum Push/Pull Force: Manway Access: Lightweight Positioner Weight: Hose Guide Assembly Weight: Pitch Adjustment Range: Control Box Weight: Maximum Air Supply Pressure: System Operating Pressure: Recommended Operational Temperature Range: DESCRIPTION OF EQUIPMENT AND INTENDED USE The AUTOBOX (ABX-2L-V2) System consists of the AUTOBOX (ABX-2L-V2) Hose Tractor, Control Box, Hose Guide Assembly, and Lightweight Positioner. This system was developed for Hands Free heat exchanger tube cleaning applications. It is recommended to be used with StoneAge s Banshee line of self-rotary waterblast tools. The AUTOBOX (ABX-2L-V2) System was designed to accommodate two simultaneous flex lances ranging in size from 3/2 to 8/4 matched with the appropriate BN9.5, BN13, BN15, or BN18 size Banshees. The AUTOBOX (ABX-2L-V2) Hose Tractor utilizes six synchronized drive rollers to control the rate at which the hose and Banshee tools are advanced or retracted within the exchanger tubes. The Hose Guide Assembly provides anti-withdrawal protection, and precise tube pitch adjustment. The Lightweight Positioner can be mounted to a variety of heat exchanger tube bundles and has pneumatic powered horizontal and vertical drives. The Control Box is small and lightweight with an emphasis on ergonomics. The AUTOBOX (ABX-2L-V2) system was designed with simplicity, safety, lightweight components, durability, and reliability in mind. It can be easily carried to the job site and setup in minutes. The AUTOBOX (ABX-2L-V2) must not be put into service within the European Community ( EC ) until the final machinery into which it is to be incorporated has been declared in conformity with the Machinery Directive and all other applicable EC Directives. 42 lbs (19.05 kg) (AUTOBOX (ABX-2L-V2) box only) 7.2 in. Wide x 8.3 in. Tall x 16.7 in. Long (183 mm Wide x 211 mm Tall x 424 mm Long) 3.0 ft/sec (914 mm/sec) 0.2 ft/sec (61 mm/sec) 60 lbs (30 lbs per lance) (27.2 kg, 13.6 kg per lance) 10 lbs (5 lbs per lance) (4.5 kg), (2.25 kg per lance) 18 in. (457 mm) 120 lbs (54.4 kg) (Includes 6ft rails, horiz., vert., and idler carriage, and 4 clamps) 6 lbs (2.7kg) 5/8-2½ in. (16 mm- 63 mm) 43 lbs (19.5 kg) (Includes Control Box, FRL, and stand) 125 psi (0.86 MPa) 100 psi (0.70 MPa) -20 F to 140 F (-29 C to 60 C) KEY FEATURES: Lightweight Positioner Modular, lightweight design Quick install drive carriages Utilizes 2.5 in. (6 mm) box rail Stainless Steel air motors Variety of clamp and bolt-on attachment options are available Hose Guide Assembly Compact and lightweight design Precise pitch adjustment Quick change guide tubes 17-4 SS hose stop collets AUTOBOX (ABX-2L-V2) Hose Tractor Six powered drive rollers ensure traction in all Operating conditions Quick change drive rollers (three sizes). Lightweight and compact design Can be used in dual or single lance applications Quick pin attachment to Hose Guide Assembly Hinged side doors for easy access to rollers and Drive components Independent forward/reverse speed controls Control Box Small, lightweight, ergonomic design that includes a Portable stand and filter-regulator-lubricator assembly Tractor controls: forward/reverse hose feed and clamp pressure Positioner controls: left/right and up/down Pneumatic dump control switch

4 CE DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY We: StoneAge, Inc. 466 South Skylane Drive Durango, CO 81303, USA Declare that this partly completed machinery supplied with this declaration: Equipment: AUTOBOX Hose Tractor Model name: ABX-2L-V2 is in accordance with the following Directives: and is designed and manufactured solely as a non-functional component to be incorporated into a machine requiring completion; must not be put into service within the European Community ( EC ) until the final machinery into which it is to be incorporated has been declared in conformity with the Machinery Directive and all other applicable EC Directives; and is designed and manufactured to comply with the 2006/42/EC Essential Health and Safety Requirements of the Machinery Directives and the relevant parts of the following specifications: EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduction We hereby declare that the equipment named above has been tested and found to comply with the relevant sections of the above referenced specifications and directives. Date _ 07/01/2015 StoneAge Europe Unit 2, Britannia Business Centre Britannia Way Malvern WR14 1GZ United Kingdom The Technical File for the AUTOBOX Hose Tractor (ABX-2L-V2) is maintained at: StoneAge, Inc. 466 South Skylane Drive, Durango, CO 81303, USA

5 WARNING AND SAFETY INSTRUCTIONS OPERATOR TRAINING Managers, Supervisors, and Operators MUST be trained in Health and Safety Awareness of High-pressure Water Jetting and hold a copy the Water Jetting Association (WJA) Code of Practice, or equivalent (see Operators MUST be trained to identify and understand all applicable standards for the equipment supplied. Operators should be trained in manual handling techniques to prevent bodily injury. Operators MUST read, understand, and follow the Operational and Training Requirements (Section 7.0) of WJTA-IMCA s Recommended Practices For The Use Of High-pressure Water jetting Equipment, or equivalent. Operators MUST read, understand, and follow the Warnings, Safety Information, Assembly, Installation, Connection, Operation, Transport, Handling, Storage, and Maintenance Instructions detailed in this manual. StoneAge has designed and manufactured this equipment considering all hazards associated with its operation. StoneAge assessed these risks and incorporated safety features in the design. StoneAge WILL NOT accept responsibility for the results of misuse. IT IS THE RESPONSIBILITY OF THE INSTALLER/OPERATOR to conduct a job specific risk assessment prior to use. Job specific risk assessment MUST be repeated for each different set up, material, and location. The risk assessment MUST conform to the Health and Safety at Work Act 1974 and other relevant Health and Safety legislation. The risk assessment MUST consider potential material or substance hazards including: Aerosols Biological and microbiological (viral or bacterial) agents Combustible materials Dusts Explosion Fibers Flammable substances Fluids Fumes Gases Mists Oxidizing Agents PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS Use of Personal Protective Equipment (PPE) is dependent on the working pressure of water and the cleaning application. Managers, Supervisors, and Operators MUST carry out a job specific risk assessment to define the exact requirements for PPE. See Protective Equipment for Personnel (Section 6) of WJTA- IMCA s Recommended Practices For The Use Of High-pressure Waterjetting Equipment for additional information. Hygiene - Operators are advised to wash thoroughly after all waterjetting operations to remove any waterblast residue which may contain traces of harmful substances. First aid provision - users MUST be provided with suitable first aid facilities at the operation site. PPE may include: Eye protection: Full face visor Foot protection: Kevlar brand or steel toe capped, waterproof, non-slip safety boots Hand protection: Waterproof gloves Ear protection: Ear protection for a minimum of 85 dba Head protection: Hard hat that accepts a full face visor and ear protection Body protection: Multi-layer waterproof clothing approved for waterjetting Hose protection: Hose shroud Respiratory protection: May be required; refer to job specific risk assessment SAFETY LABEL DEFINITIONS The AUTOBOX (ABX-2L-V2) Hose Tractor has the potential to cause serious injury if fingers, hair, or clothing become caught between the hose rollers or drive belts. DO NOT OPERATE WITH THE DOORS OPEN. ENSURE THAT ALL FOUR DOOR PINS ARE SECURED PRIOR TO OPERATION. Maximum operating air pressure is 100 psi (0.7 MPa). Never exceed 125 psi (0.86 MPa) supply pressure. Exceeding 125 psi (0.86 MPa) supply pressure may result in injury to the Operator and/or damage to the equipment

6 WARNING AND SAFETY INSTRUCTIONS WARNING Operations with this equipment can be potentially hazardous. Caution MUST be exercised prior to and during machine and water jet tool use. Please read and follow all of these instructions, in addition to the guidelines in the WJTA Recommended Practices handbook, available online at Deviating from safety instructions and recommended practices can lead to severe injury and/or death. Do not exceed the maximum operating pressure specified for any component in a system. The immediate work area MUST be marked off to keep out untrained persons. Inspect the equipment for visible signs of deterioration, damage, and improper assembly. Do not operate if damaged, until repaired. Make sure all threaded connections are tight and free of leaks. Users of the AUTOBOX (ABX-2L-V2) Hose Tractor MUST be trained and/or experienced in the use and application of high pressure technology and cleaning, as well as all associated safety measures, according to the WJTA Recommended Practices for the use of High pressure Water jetting Equipment. An anti-withdrawal device (back-out preventer) MUST be used at all times. The back-out prevention device is the Hose Stop Collet located within the Hose Guide Assembly. StoneAge offers several different size Hose Stop Collets. The Collet Size Reference guide is located on the Hose Guide Assembly. The Control Box should be located in a safe location where the Operator has good visibility of the tool entering the exchanger tubes. The AUTOBOX (ABX-2L-V2) Hose Tractor and Control Box MUST be supervised at all times and should never be left unattended. Do not fully release the hose clamp (decreasing pressure to zero) during operation, or the AUTOBOX (ABX-2L-V2) Hose Tractor will release the hose and may create a dangerous runaway hose condition, which can result in severe injury and/ or death. Always de-energize the system before opening the door to service or replace any parts. Failure to do so can result in severe injury and/or death. When moving the AUTOBOX (ABX-2L-V2) Hose Tractor lift with care to prevent bodily injury. Do not operate the AUTOBOX (ABX-2L-V2) Hose Tractor while either side door is open. PRE-RUN SAFETY CHECK Refer to WJTA-IMCA s, Recommended Practices For The Use Of High pressure Waterjetting Equipment and/or The Water Jetting Association s, WJA Code of Practice for additional safety information. Complete a job specific risk assessment and act on the resulting actions. Adhere to all site specific safety procedures. Ensure the waterblasting zone is properly barricaded and that warning signs are posted. Ensure the work place is free of unnecessary objects (e.g. loose parts, hoses, tools). Ensure all Operators are using the correct Personal Protective Equipment (PPE). Check that the air hoses are properly connected and tight. Check all hoses and accessories for damage prior to use. Do not use damaged items. Only high quality hoses intended for waterblast applications should be used as high pressure hoses. Check all high pressure threaded connections for tightness. Ensure that an anti-withdrawal device (back-out preventer), whip checks (hose whips), and all other applicable safety devices are installed and set-up properly. Ensure the doors of the AUTOBOX (ABX-2L-V2) Hose Tractor are closed and securely latched. Test the Control Box before operating the AUTOBOX (ABX- 2L-V2) Hose Tractor with high pressure water to verify the control valves move the hose in the intended direction, and that the high pressure dump valve and hose clamp are working properly. Ensure that Operators never connect, disconnect, or tighten hoses, adapters, or accessories with the high pressure water pump unit running. Ensure no personnel are in the hydroblasting zone

7 SYSTEM ASSEMBLY - OVERVIEW AUTOBOX (ABX-2L-V2) HOSE TRACTOR, LIGHTWEIGHT POSITIONER, HOSE GUIDE ASSEMBLY, AND CONTROL BOX LIGHTWEIGHT POSITIONER (SEE PAGES 8, 9, 10, 11) CONTROL BOX (SEE PAGES 19, 20, 21, 22) AUTOBOX (ABX-2L-V2) HOSE TRACTOR (SEE PAGES 15, 16, 17, 18) HOSES RUN TO HIGH PRESSURE WATER SUPPLY HOSE GUIDE ASSEMBLY (SEE PAGES 12, 13, 14, 18) NOTE: Heat exchanger tube bundle face, shown for graphic representation only. Not included in assembly

8 LIGHTWEIGHT POSITIONER - OVERVIEW LIGHTWEIGHT POSITIONER AND ACCESSORIES RAIL STOP ASSEMBLIES HORIZONTAL DRIVE ASSEMBLY RAIL EXTENSIONS (2,4, OR 6 FT LENGTHS) (.61 m, 1.2 m, OR 1.8 m) VERTICAL SLOTTED RAIL POSITIONER CONTROL LINES HORIZONTAL SLOTTED RAIL 25 FT / 7620 mm STANDARD LENGTH CLAMP TYPES (LWP 625 KIT INCLUDES ALL KITS SHOWN HERE) VERTICAL DRIVE ASSEMBLY NON-SLOTTED RAIL SLOTTED QUICK CLAMP (LWP 620 KIT CONTAINS 4) QUICK CLAMP (LWP 621 KIT CONTAINS 4) PLATE CLAMP (LWP 622 KIT CONTAINS 2) BLANK HORIZONTAL ASSEMBLY SCAFFOLD QUICK CLAMP (LWP 554-K KIT CONTAINS 4) RAIL STOP ASSEMBLY

9 LIGHTWEIGHT POSITIONER CLAMP SELECTION CLAMP SELECTION is dependent upon the heat exchanger geometry, bolt holes, hole spacing, and flange accessibility. QUICK CLAMPS (LWP 518) are for use with heat exchanger flanges that provide a robust clamping surface or if flange holes are inaccessible. Align clamps on the surface of the flange to maximize flange engagement to clamps. (Figure 1) \ QUICK CLAMP (LWP 621 KIT CONTAINS 4) FIGURE 1 SLOTTED QUICK (LWP 552) AND PLATE CLAMPS (LWP 519) are for use with heat exchanger flanges that have easily accessible bolt holes. Use quick clamps or plate clamps, depending on the spacing of the hole pattern. (Figures 1 & 3) SLOTTED QUICK CLAMP (LWP 620 KIT CONTAINS 4) PLATE CLAMP (LWP 622 KIT CONTAINS 2) FIGURE 2 FIGURE 3 SCAFFOLD QUICK CLAMPS (LWP 554) are for use with scaffolding in situations where they may be no way to clamp directly onto the heat exchanger. (Figure 4) SCAFFOLD QUICK CLAMP (LWP 554-K KIT CONTAINS 4) FIGURE

10 LIGHTWEIGHT POSITIONER SET-UP LIGHTWEIGHT POSITIONER STEP BY STEP SET-UP 1. Mount the appropriate frame Positioner Clamps to the tube bundle as shown on the previous page. (Shown in Figure 1 with Slotted Quick Clamps) Positioner Clamps should be aligned horizontally with the direction of the tube rows. (Figure 1) NOTE: Heat exchanger tube bundle face, shown for graphic representation only. Not included in assembly. FIGURE 1 2. Insert the Top Rail (slots facing out) into the upper mounting brackets. If the rail is not closely aligned with the tube rows, loosen one of the upper mounting brackets and adjust until the top rail is parallel with the horizontal tube rows. Tighten the clamps securing the rail to the mounting brackets. Ensure upper mounting brackets are securely clamped or bolted to the tube bundle flange. (Figure 2) FIGURE 2 3. Insert the Lower Rail (non-slotted) into the lower mounting brackets. It is not critical that this rail is aligned as precisely as the top rail, but it should be close to parallel with the top rail for best performance. Tighten the clamps securing the rail to the mounting brackets. Ensure lower mounting brackets are securely clamped or bolted to the tube bundle flange. (Figure 3) FIGURE 3 4. Loosen the Quick Adjust Handle and pull the gearbox away from the carriage plate. This will allow the Horizontal Drive Carriage to slide onto the rail without pneumatic power, to rotate the drive. Center the carriage on the top rail and push the gearbox back toward the carriage plate. This will engage the gear into the rail slots. Verify the gear is engaging the slots correctly and tighten the quick adjust handle. (Figure 4) FIGURE

11 LIGHTWEIGHT POSITIONER SET-UP 5. Slide the Idler Carriage onto the Lower Non-Slotted Rail. (Figure 5) FIGURE 5 6. Loosen the Large Adjustable Handle for the Vertical Rail Clamp. Align the Idler Carriage with the vertical rail clamp on the horizontal carriage. Install the Vertical Rail with (slots facing out) down through the horizontal carriage clamp and between the rollers on the idler carriage. Adjust the position of the vertical rail as required and secure the clamp on the horizontal carriage by tightening the large adjustable handle. (Figure 6) FIGURE 6 7. Loosen the Quick Adjust Handle and pull the gearbox away from the carriage plate. This will allow the Vertical Drive Carriage to slide onto the rail without pneumatic power to rotate the drive. Center the carriage on the vertical rail and push the gearbox back toward the carriage plate. This will engage the gear into the rail slots. Verify the gear is engaging the slots correctly and tighten the quick adjust handle. (Figure 7) FIGURE 7 8. Install the four Rail Stops at both ends of the top, slotted, horizontal rail, and both ends of the vertical slotted rail. (Figure 8) NOTE: Verify the mounting brackets and rail clamps are securely tightened, and the drive carriages are securely engaged, and the adjustable handles are tightened. Never loosen the vertical gearbox once the Hose Guide Assembly and tractor are installed, as it may result in the carriage falling vertically down. This may cause damage to the equipment and/or injury. FIGURE

12 HOSE GUIDE ASSEMBLY - OVERVIEW ABX-201 HOSE GUIDE ASSEMBLY PITCH ADJUST HANDLE ABX 117-XX GUIDE TUBES (MULTIPLE SIZES AVAILABLE) GUIDE TUBE CLAMP HANDLE ABX-121-XX COLLET (MULTIPLE SIZES AVAILABLE) MOUNTING BRACKET QUICK RELEASE PIN HIGH VISIBILITY HOUSING HOSE STOP CLAMPS (MULTIPLE SIZES AVAILABLE) *OPTIONAL ABX 140-XX GUIDE TUBE ANTI-TWIST CLAMP DESIGNED TO KEEP PITCH ALIGNMENT BETWEEN LONGER GUIDE TUBES SEE PART DIAGRAM PAGES FOR SIZING

13 HOSE GUIDE ASSEMBLY SET-UP HOSE GUIDE ASSEMBLY 1. Select the appropriate Guide Tube size and length for the application from the chart at the bottom of the previous page. The length of the Guide Tubes for an exchanger bundle with no channel head is 12.5 in. (318 mm). A deeper channel head will require extended Guide Tubes. The depth of the channel head added to the 12.5 in. (318 mm) length will give the desired tube length. Longer guide tubes are available if required for use with channel heads. ROLLER HOSE O.D. SPIR STAR Ø 1.94 IN. ORANGE Ø 1.85 IN. BLACK Ø 1.75 IN. BLUE NOTICE The Banshee tool should not have excessive clearance if the correct length Guide Tube size is used. 2. To remove the existing Guide Tubes, loosen the Tube Clamp Lever and the Pitch Adjust Lever, located on top of the Hose Guide Assembly. After selecting the appropriate Guide Tubes, install the Guide Tubes into the Hose Guide Assembly. 3. Secure the Guide Tubes by tightening the Tube Clamp Lever and Pitch Adjust Lever, when the desired pitch has been set. 4. Select the appropriate Collet and Hose Stops from the chart on the previous page and reserve them for future Hose and Collet installation instructions in this manual. WARNING in (7 mm - 10 mm) in (11 mm - 13 mm) in (13 mm - 16 mm) 2 Appropriate size Collet selection is CRITICAL to ensuring proper backout prevention of the tool. 3 PARKER COLLET SIZE COLLET PART NUMBER 2 3 HOSE STOP SIZE 1 HOSE STOP PART NUMBER 3/2 2240D in. / 8 mm ABX / 7-9 mm HS /4, 4/2 2240D-025, 2440D in. / 8 mm ABX / 7-9 mm HS /6, 5/2 2240D in. / 10 mm ABX / 9-11 mm HS /4 2448D in. / 11 mm ABX / 9-11 mm HS /6, 5/4, 6/2 2240D in. / 12 mm ABX / mm HS D D in. / 12 mm ABX / mm HS /4 2440D in. / 13 mm ABX / mm HS /6, 8/2 2240D-05, 2740D in. / 14 mm ABX / mm HS /4.594 in. / 14 mm ABX / mm HS D in. / 15 mm ABX / mm HS StoneAge (SA) PART NUMBER GUIDE TUBE REFERENCE CHART GUIDE TUBE BANSHEE INSIDE DIAMETER, LENGTH ABX BN in / 12 mm, 12.5 in. / 318 mm ABX BN in / 12 mm, 36 in. / 914 mm ABX BN in / 14 mm, 12.5 in. / 318 mm ABX BN in / 14 mm, 36 in. / 914 mm ABX BN in / 17 mm, 12.5 in. / 318 mm ABX BN in / 17 mm, 36 in. / 914 mm ABX BN in / 19 mm, 12.5 in. / 318 mm ABX BN in / 19 mm, 36 in. / 914 mm

14 HOSE GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER SET UP ATTACH HOSE GUIDE ASSEMBLY TO LIGHTWEIGHT POSITIONER 1. Using a 9/16 in. wrench, loosen all four rail clamp bolts located on the vertical carriage. Install the Hose Guide Assembly into the rail clamps and adjust position until the Guide Tubes are approximately 1/2 in. (13 mm) away from the tube sheet face. Tighten the four rail clamp bolts. 2. Loosen the Pitch Adjustment Levers and adjust the guide tubes until they are in line with pitch of the tubes in the bundle. 3. Tighten Tube Clamp and Pitch Adjustment Levers until tubes are secured in position. Heat exchanger tube bundle face /2 (13 mm) Adjust position until the Guide Tubes are approximately 1/2 in. (13 mm) away from the face of the heat exchanger

15 ABX-2L HOSE TRACTOR - OVERVIEW AUTOBOX (ABX-2L-V2) HOSE TRACTOR HANDLE ROLLER AND COLLET REFERENCE CHART COLOR CODED JIC FITTINGS WITH DUST CAPS DOOR PIN FORWARD AND REVERSE SPEED CONTROLS QUICK RELEASE PIN MOUNTING BRACKET DRIVE ROLLERS DOOR QUICK RELEASE PINS MOUNTING BRACKET FOR HOSE GUIDE ASSEMBLY PNEUMATIC SUPPLY LINES (COME BUNDLED IN NYLON SHEATH) PNEUMATIC SUPPLY LINE PACKAGE 25 FT / 7620 mm

16 ABX-2L HOSE TRACTOR - DOORS AND PINS DOOR Always run the AUTOBOX (ABX-2L-V2) Hose Tractor with the doors closed and locked. DOOR PIN The Door Pin is a spring plunger with a pull ring. To unlock the door, pull and twist the pull ring, then release it so that it is no longer in the groove. Close the door by raising it into position. To lock the door, pull and twist the pull ring, then release it into the groove of the pin. NOTE: Make sure to lock both doors on each side of the Hose Tractor before operating AUTOBOX (ABX-2L-V2) Hose Tractor. UNLOCKED OPEN DOOR POSITION LOCKED DOOR PIN DOOR PINS CLOSED DOOR POSITION

17 ABX-2L HOSE TRACTOR - DRIVE ROLLERS ROLLER HOSE O.D. SPIR STAR Ø 1.94 IN. ORANGE Ø 1.85 IN. BLACK Ø 1.75 IN. BLUE in (7 mm - 10 mm) in (11 mm - 13 mm) in (13 mm - 16 mm) PARKER COLLET SIZE COLLET PART NUMBER HOSE STOP SIZE HOSE STOP PART NUMBER 3/2 2240D in. / 8 mm ABX / 7-9 mm HS /4, 4/2 2240D-025, 2440D in. / 8 mm ABX / 7-9 mm HS /6, 5/2 2240D in. / 10 mm ABX / 9-11 mm HS /4 2448D in. / 11 mm ABX / 9-11 mm HS /6, 5/4, 6/2 WARNING Always de-energize the system before servicing or replacing any parts. Failure to do so can result in severe injury and/or death. Keep hands, hair, and clothing clear of rotating parts. TO REPLACE THE DRIVE ROLLERS: 1. Select the correct roller size for the particular hose being used: 2240D in. / 12 mm ABX / mm HS D D in. / 12 mm ABX / mm HS /4 2440D in. / 13 mm ABX / mm HS /6, 8/2 2240D-05, 2740D in. / 14 mm ABX / mm HS /4.594 in. / 14 mm ABX / mm HS D in. / 15 mm ABX / mm HS ABX 272 (ORANGE) ABX 271 (BLACK) ABX 273 (BLUE) 2. Slowly run the Drive Rollers in order to orient the key ways of the Drive Rollers upward and the spring plungers downward. NOTE: Rollers should be removed with the keyway facing up to prevent losing keys. 3. Use a small common screwdriver or similar tool to depress the ball spring plunger, and pull the rollers straight out from the shafts. 4. Prior to reinstalling the Drive Rollers onto the shafts, apply a liberal coat of Anti-seize to the shaft OD and keys. We recommend Mariners Choice Never-Seez. 5. Install the Drive Rollers by sliding into place until the spring plungers snap out. NOTE: Drive Rollers should be installed with the keyway facing up to prevent losing keys. 6. Once the correct Drive rollers are installed, close and lock the doors. The Hose Tractor can now be installed onto the Hose Guide. SPRING PLUNGER ORIENTATION KEY WAY DRIVE ROLLERS (X6)

18 ABX-2L HOSE TRACTOR TO GUIDE ASSEMBLY ATTACH AUTOBOX (ABX-2L-V2) HOSE TRACTOR TO HOSE GUIDE ASSEMBLY 1. Remove the lower quick release pin from the AUTOBOX (ABX-2L-V2) Hose Tractor. 2. Slide the mounting bracket over the block on the Hose Guide Assembly and lay the pin onto the top slot on the Hose Guide Assembly mounting block. 3. Install the lower pin through the mounting bracket on the Hose Tractor and the block on the Hose Guide Assembly The tractor is now securely mounted to the Hose Guide Assembly

19 CONTROL BOX - OVERVIEW CONTROL BOX TOP VIEW MOMENTARY PNEUMATIC DUMP CONTROL HOSE FEED LEVER HOSE CLAMP PRESSURE REGULATOR HOSE CLAMP PRESSURE GAUGE POSITIONER CONTROLS CONTROL BOX FRONT VIEW CONTROL BOX REAR VIEW MAIN BOX FRAME POLE MOUNT WITH THUMB SCREW 1/4 (6 mm) PUSH CONNECT PNEUMATIC DUMP VERTICAL CONTROL FITTING POSITIONER FITTINGS WITH DUST CAPS PRESSURE REGULATOR FILTER, REGULATOR, LUBRICATOR INLET AIR FITTING TRIPOD LEGS INLINE OILER FEED ADJUSTMENT AIR SUPPLY FITTING WITH DUST CAP COLOR CODED JIC FITTINGS WITH DUST CAPS HORIZONTAL POSITIONER FITTINGS WITH DUST CAPS COLOR CODED JIC FITTING WITH DUST CAP

20 CONTROL BOX SET-UP ASSEMBLE CONTROL BOX, FRL, AND TRIPOD BASE 1. Setup the tripod base in a location with good visibility to the bundle face, but at a safe distance away from waterblast zone. 2. Slide the vertical tube into the tripod base. Secure with the supplied thumbscrew knob. Note: The vertical tube has a hole through one wall that the thumbscrew must engage. 3. Slide the Filter, Regulator, Lubricator (FRL) assembly over the vertical tube down to the tripod base. Secure with the supplied thumbscrew knob. Note: The vertical tube has a hole through one wall that the thumbscrew must engage. 4. Slide the Control Box over the vertical tube. The Control Box has a stop that keeps it located at the top of the vertical tube. Secure with the supplied thumbscrew knob. 5. Install and tighten the short 1/2 in. (13 mm) I.D. hose between the FRL and the Control Box. FILTER, REGULATOR, LUBRICATOR, ASSEMBLY (FRL) THUMBSCREW KNOB (ALIGN WITH PRE-DRILLED HOLE ON TUBE INSERT) THUMBSCREW KNOB (ALIGN WITH PRE-DRILLED HOLE ON TUBE INSERT) TUBE INSERT THUMBSCREW KNOB

21 CONTROL BOX AIR SUPPLY FITTING AIR SUPPLY AND LUBRICATOR SETTING 1. The Control Box is supplied with a twist claw style inlet coupling (Chicago style) located on the side of the FRL Assembly. Connect a compatible compressed air line (not included) according to the Manufacturer s instructions. If another pneumatic connection is preferred, this fitting can be removed and any male 1/2 in (13 mm) NPT fitting may be used. 2. Using the regulator adjust the operating air pressure to 100 psi (0.7 MPa) for the application. WARNING Maximum operating air pressure is 100 psi (0.7 MPa). Never exceed 125 psi (0.86 MPa) supply pressure. Exceeding 125 psi (0.86 MPa) supply pressure may result in injury to the Operator and/or damage to the equipment. AIR SUPPLY FITTING A universal AIR SUPPLY FITTING (Chicago style) is located on the FRL. Connect a compatible compressed air line (not included) according to the Manufacturer s instructions. If another pneumatic connection is preferred, this fitting can be removed and any male ½ in (13 mm) NPT fitting may be used. ADJUST INLINE OILER TO FEED 1 DROP OF OIL EVERY SECONDS FOR HIGH SPEED OR CONTINUOUS DUTY USAGE PNEUMATIC DUMP CONTROL FITTING AND LINE A MOMENTARY PNEUMATIC DUMP CONTROL is located on the Control Box panel and can be set up to control an air actuated dump valve. To utilize the toggle, the end user will need to install 1/4 in. (6 mm) O.D. nylon tubing (not included) between the PNEUMATIC DUMP CONTROL FITTING and the pneumatic dump valve. PNEUMATIC DUMP CONTROL FITTING ¼ IN OD TUBING (NOT INCLUDED) CONTROL BOX REAR VIEW

22 CONTROL BOX TO AUTOBOX (ABX-2L-V2) HOSE TRACTOR ASSEMBLY PNEUMATIC SUPPLY LINE CONNECTIONS 1. Remove the dust caps from the Joint Industry Council (JIC) fittings of the Control Box and the AUTOBOX (ABX-2L-V2) Hose Tractor. 2. Connect the AUTOBOX (ABX-2L-V2) Hose Tractor to the Control Box with two 1/2 in. (13 mm) JIC hoses and one 1/4 in. (6 mm) JIC hose. Verify the Control Box rotates the rollers in the appropriate direction and that the clamp functions correctly. 3. Connect the horizontal positioner drive air motor to the Control Box with two 1/4 in. (6 mm) JIC hoses. Verify the Control Box moves the horizontal carriage in the appropriate direction. 4. Connect the vertical positioner drive air motor to the Control Box with two 1/4 in. (6 mm) JIC hoses. Verify the Control Box moves the vertical carriage in the appropriate direction. 5. Test the Control Box before operating the AUTOBOX (ABX- 2L-V2) Hose Tractor with high pressure water to verify the control valves move the hose in the intended direction, and that the dump valve is working properly. REAR VIEW FORWARD LEFT UP REVERSE RIGHT DOWN CLAMP Note: The 4 Positioner control lines are not color coded. Colors are shown in manual for clarity

23 OPERATION COLLET INSERTION, HOSE, AND HOSE STOP INSTALLATION 1. Remove Quick Release Pin and pull out existing Collet. 2. Insert Banshee tool on hose through the AUTOBOX (ABX-2L-V2) Hose Tractor, and hose Hose Guide Assembly. Be sure that the Banshee tool and hose end pass the location of the Collet. 3. Select the appropriate Collet size for the diameter of the hoses. (See Recommended Collets For Common Hose Sizes plaque on the top plate of the ABX-2L-V2 Tractor or the side of the vertical carriage on the Lightweight Positioner.) 4. Install the Collet and quick release pin. 5. Pull on the hoses from the back of the AUTOBOX (ABX-2L-V2) Hose Tractor to ensure that the Collet does not allow the Banshee to back out of the Guide or Hose Tractor. 6. To install hose stops, push tool through until the tips are 1-2 (25-51 mm) past the end of the tube bundle. Loosely install the stop, then push toward the mounting bracket and tighten in place. 1 WARNING Appropriate size Collet selection is CRITICAL to ensuring proper anti-withdrawal prevention of the tool. See Recommended Collets For Common Hose Sizes plaque on the top plate of the ABX-2L-V2 Tractor or the side of the vertical carriage on the Lightweight Positioner. 2 COLLET REMOVED BANSHEE TOOL WITH HOSE END, MUST BE PAST THE COLLET SLOT BEFORE INSERTING THE COLLET 4 COLLET INSERTED

24 OPERATION CONTROL PANEL FUNCTIONS HOSE FEED LEVER- The HOSE FEED LEVER will move the hose in the forward (feeding) and reverse (retracting) directions. The OFF position is at the spring centered middle position and will stop the Drive Rollers from turning. The speed controls are located on the AUTOBOX (ABX-2L-V2) Hose Tractor. Speed is independently adjustable for Forward/Reverse. Minimum speed is.2ft/sec (6 cm/sec). Maximum speed is 3.0ft/sec (914 mm/sec). POSITIONER CONTROLS- UP/DOWN will move the PRODRIVE Tractor (ABX-PRO) up and down the tube face bundle. Push forward to move the assembly UP, release to STOP the motion, push down to move the assembly down. LEFT/RIGHT will move the PRODRIVE Tractor (ABX-PRO) from side to side along the tube face bundle. Push left to move the assembly to the LEFT, release the lever to STOP the motion, push RIGHT to move the assembly to the right. MOMENTARY PNEUMATIC DUMP CONTROL- To use the DUMP CONTROL, hold it in the FORWARD position to route the high-pressure water to the tool. Release the knob to divert the high-pressure water away from the tool. To de-energize the system, release the HOSE FEED LEVER and rel ease the MOMENTARY PNEUMATIC DUMP CONTROL. This will stop the Drive Rollers from moving and reroute the high-pressure water away from the AUTOBOX (ABX-2L-V2) Hose Tractor. TEST RUN PROCEDURE Perform the PRE-RUN SAFETY CHECK (SEE PAGE 6). Ensure appropriate Collet is installed and hose clamp pressure is set at 20-30psi ( MPa) Operate the high-pressure hose and waterjet tool at full pressure to test the clamp force. Proper clamp force will provide good control of the hose in forward and reverse directions. Adjust the hose feed speed controls. Proper forward and reverse speeds will vary, depending on the type of material being removed and the tube size. Adjustment of the hose feed speed controls may be necessary during operation in order to optimize cleaning and overall productivity. Operate the high-pressure water at full pressure and use the MOMENTARY PNEUMATIC DUMP CONTROL to verify that the dump valve is working properly. RUN PROCEDURE After assembling and verifying, the AUTOBOX (ABX-2L-V2) Hose Tractor system is ready for operation. Once all hose connections have been secured and verified, it is recommended to flush the hoses and verify the dump valve is working properly before installing the Banshee tools. After flushing the hoses, install the Banshee tools and insert both tools into the back of the AUTOBOX (ABX-2L-V2) Hose Tractor. It may be necessary to twist the hoses slightly as the tools and hose ends are manually pushed through the Drive Rollers. Once the Banshees are inside the Guide Tubes, install the Collet (anti-withdrawal protection). The appropriate Collet must be verified, installed, secured, tested, and performance confirmed before operating at high pressure. Adjust the clamp pressure to psi. ( MPa). Align the Guide Tubes with an open set of tubes in the heat exchanger bundle. Feed forward and advance the hoses into the tube bundle at low pressure and wait for the tools to exit the far side of the heat exchanger. Set the forward hose stops in the desired position to ensure the entire tube is cleaned, but that the hose crimp does not fully exit the tube. Retract the hoses into the Guide Tubes. Close the dump and gradually increase the pump to the desired operating pressure. Feed forward and advance the hoses into the tube bundle. Dump and make any desired changes to forward and/or reverse operating speeds. If the Drive Rollers are slipping excessively, increase the clamp pressure. It is recommended to operate the clamp pressure as low as possible without excessive slippage. Optimal clamp pressure is achieved when the Drive Rollers slip ½ to 1 full rotation after hitting the hose stops (forward) or the Collet engages the hose crimp (reverse). It is recommended to use hose supplied with the secondary crimp so the (anti-withdrawal protection) Collet does not impact the pressure containing crimp. Operate the left/right and up/down positioner functions to begin high pressure cleaning at the preferred location on the tube bundle. Always align the Guide Tubes as closely as possible with the heat exchanger tubes before advancing the hoses When operating the AUTOBOX (ABX-2L-V2), an obstacle or restriction within a heat exchanger tube may be encountered. When this occurs, the AUTOBOX (ABX-2L-V2) is designed to slow and stall the air drive motor, stopping the advancement of the hose, lance, and Banshee tool. The operator should stop forward feed and reverse the lance feed direction, backing the tool away from the obstruction. Repeat the back and forth operation, until the resistance or obstruction is cleared via the cleaning action of Banshee tool at the end of the hose. The AUTOBOX (ABX-2L-V2) is not designed for Drive Roller slip. If slippage occurs, gradually increase the clamp force using the HOSE CLAMP PRESSURE REGULATOR on the Control Box

25 OPERATION HIGH-PRESSURE HOSE The AUTOBOX (ABX-2L-V2) Hose Tractor is designed to be used with Parker Pro-Lance and/or Spir Star Blast-Pro hose ends. Standard hose ends may not fit into Hose Tractor and/or Guide Tubes. Note: MAXIMUM hose end diameter must NOT exceed.71 in. (18 mm) Only high quality hoses intended for waterblast applications should be used as high-pressure hoses. Pressure rating of high-pressure hoses MUST NEVER be exceeded. Verify that the high-pressure hose is properly installed in the back-out preventer. Operate the high-pressure hose and waterjet tool at full pressure to test the clamp force. Proper clamp force will provide good control of the hose in forward and reverse directions, and keep the hose running through the Drive Rollers. The AUTOBOX (ABX-2L-V2) Hose Tractor MUST be supervised at all times. HOSE LENGTHS The ABX-2L-V2 has a variety of accessories that will require additional hose length to be considered in addition to the tube bundle length. This should be verified prior to ordering high pressure hose for each job. The chart below shows the actual length of each configuration and recommended additional length necessary to keep the assembly from lifting off the ground during operation. Provide the tube bundle length and use the chart to follow the calculation below to determine the total hose length. (Tube Bundle Length, in./mm) + (Actual Length of Configuration, in./mm) + (Recommended Additional Connection Length, in./mm) = Total Hose Length in./mm ACCESSORY CONFIGURATIONS NOTICE Do not use a shrouded hose or hose with a steel protective cover. This will cause severe damage to the Drive Rollers. Open the door to install the high-pressure hose. The HOSE CLAMP PRESSURE REGULATOR on the Control Box MUST be turned to zero pressure to open the Drive Rollers for easy hose installation. Insert the hose, equipped with the waterjet tool, between the Drive Rollers. Increase the pressure on the HOSE CLAMP PRESSURE REGULATOR to extend the clamp rollers and clamp the hose. Close and lock the door before operating the AUTOBOX (ABX-2L-V2) Hose Tractor. Test the Control Box before operating the AUTOBOX (ABX-2L-V2) Hose Tractor with high-pressure water to verify the control valves move the hose in the intended direction, and that the dump valve is working properly. HOSE CLAMP ACTUAL LENGTH OF CONFIGURATION The Drive Rollers are controlled by turning the HOSE CLAMP PRESSURE REGULATOR. Use the HOSE CLAMP PRESSURE GAUGE to record desired pressure for future use. Clamp force will not damage hoses. Proper clamp force will provide good control of the hose in forward and reverse directions, and will keep the hose running through the Drive Rollers. WARNING RECOMMENDED ADDITIONAL CONNECTION LENGTH ABX-2L, Hose Guide, and Lightweight Positioner 32.9 in / 836 mm 39 in / 991 mm ABX-2L, Hose Guide, Lightweight Positioner, and HCS in / 3683 mm 39 in / 991 mm ABX-2L, Fin Fan Guide, Fin Fan Snout in / 3264 mm 39 in / 991 mm ABX-2L, Fin Fan Guide, Fin Fan Snout, and HCS in / 6111 mm 39 in / 991 mm Example: The hose length equation for a 20ft (6096 mm) tube bundle with ABX-2L, Hose Guide, and Lightweight Positioner would be; STANDARD: (20ft x 12 in/ft) in + 39 in = in. METRIC: 6096 mm mm mm = 7922 mm Do not fully release the hose clamp (decreasing pressure to zero) during operation, or the AUTOBOX (ABX-2L-V2) Hose Tractor will release the hose and may create a dangerous runaway hose condition, which can result in severe injury and/or death. Crush Hazard. Keep hands, hair, and clothing clear of drive rollers and belts. Contact with moving parts can result in severe injury. CLAMP FORCE

26 MAINTENANCE Maintenance Item Frequency Maintenance Required Forward, reverse, and clamp fittings Before each use Inspect threads on fittings for wear or damage. Forward and reverse fittings After each use Apply a small amount of air tool oil directly into the forward and reverse fittings. Then, briefly operate the controls at slow speed for a short duration in each direction to coat the interior parts of the motor. Install the dust caps onto all three fittings to keep moisture and dirt out. NOTICE Do not add oil to the clamp fitting, as oil may accumulate in the air cylinders and prevent them from fully retracting. Drive Rollers After each use The Drive Rollers are very durable and should last several hundred hours. However, it is recommended to inspect all Drive Rollers for wear and/or cracks at the completion of each job. Replacement is required when wear begins to affect the hose feed in forward or reverse, or when it affects the hose alignment. It is recommended to replace all six Drive Rollers at the same time to maintain optimal performance. Belt After each use Check and adjust belt tension with the Rollers in the MAX open position. It may be necessary to install a hose or other material to hold the rollers open. NOTE: Do not use any materials with sharp edges, as they will damage the rollers. To inspect press down between the two idlers with 5 lbs of force on the belt. The belt should deflect.25 in. ±.05 in. (6 mm ±1mm). If the belt deflects more than.30 in. (8 mm) it should be tightened. (See Diagram below) All components the hoses pass through After each use NOTICE Do not use any materials with sharp edges to hold the Drive. Most wear parts are made from 17-4 PH stainless steel and should have a very long life. However, as wear occurs the rounded edges could become sharp and damage hoses. Any components showing excessive wear should be replaced. Clamp Sticking Intermittent Remove the top plate and remove any debris from between the inner plates. DO NOT USE highpressure water. Contact StoneAge for Safety Data Sheets for material usage, a complete list of spare part numbers, and service instructions for the AUTOBOX (ABX-2L-V2) Hose Tractor and Control Box. TO REPLACE THE BELT: Using a 9/16 Socket, loosen the hex head bolt and slide the idler sprocket to the right. Remove the worn belt. Install the new belt in the wrap pattern shown in diagram. SETTING TENSION: Adjust belt tension with the Drive Rollers in the MAX open position. It may be necessary to install a hose or other material to hold the rollers open. To inspect press down between the two idlers with 5 lbs of force on the belt. The belt should deflect.25 in. ±.05 in. (6 mm ±1mm). If the belt deflects more than.30 in. (8 mm) it should be tightened. (See Diagram below) FORWARD REVERSE DUST CAPS.25 in. ±.05 in. (6 mm ±1mm) CLAMP STORAGE, TRANSPORTATION, AND HANDLING The AUTOBOX (ABX-2L-V2) Hose Tractor is shipped in a custom wooden crate and should be stored upright in the same crate between jobs. When moving the AUTOBOX (ABX-2L-V2) Hose Tractor, lift with care to prevent bodily injury. When storing the unit, use compressed air to blow out the air lines to remove debris and moisture. Use mild soapy water to clean the machine in order to remove corrosive materials. Apply a small amount of air tool oil directly into the forward and reverse fittings. Then, briefly operate the controls at slow speed for a short duration in each direction to coat the interior parts of the motor. Install the dust caps onto all three fittings to keep moisture and dirt out

27 PARTS DIAGRAM AUTOBOX (ABX-2L-V2) HOSE TRACTOR # PART NUMBER QTY. 1 ABX COLLET REFERENCE PLATE 1 2 ABX CE SERIAL PLATE 1 3 ABX 205 SIDE PLATE INLET 1 4 ABX 206 SIDE PLATE OUTLET 1 5 ABX 207 PLATE, TOP 1 6 ABX 208 GUARD, BACK ASSY 1 7 ABX 210 PLATE, BOTTOM 1 8 ABX 211 DOOR ASSY 1 9 ABX 215 PULL HANDLE RUBBER GRIP GREY 10 ABX 217 HOSE GUIDE PLATE, INNER 1 11 ABX WEAR RING 2 12 ABX 220 PLATE, OUTER 1 13 ABX 221 PLATE, INNER 1 14 ABX 222 PLATE, STIFFENER 2 15 ABX 223 SHAFT, LINK 3 16 ABX 224 LINK BAR 4 17 ABX 225 SPACER, LINK ABX 226 SHAFT, DRIVE ROLLER 6 19 ABX 227 SPACER, TOP SHAFT 6 20 ABX 228 BEARING.500 ID X OD SEALED PERMALUBE 21 ABX 229 BALL PLUNGER 6 22 ABX 231 DRIVE ALUMINUM SPROCKET 32T X ABX 232 CAP, AIR MOTOR SHAFT 1 24 ABX 233 CYLINDER, SMC 1 25 ABX 234 ROD END 1 26 ABX 235 PLATE, BEARING 1 27 ABX 236 PLATE, AIR CYLINDER CLEVIS 1 28 ABX 237 CYLINDER PIVOT PLATE 1 29 ABX 238 HEADLESS CLEVIS PIN.50 OD X 1.25 SS 30 ABX 239 SLEEVE BEARING.500 ID X.6875 OD 31 ABX 240 SHAFT, IDLER SPROCKET 2 32 ABX 242 DRIVE BELT 1 33 ABX HOSE GUIDE BLOCK ABX 247 FLOW CONTROL VALVE MASC ABX 248 IDLER NUT 1 36 ABX 249 RETAINING RING, HD EXT SS 6 37 ABX 250 AIR MOTOR, GLOBE 1 38 ABX 252 PLATE, AIR MOTOR BEARING 1 39 ABX 253 STEP KEY 1 40 ABX 255 PAD, BEARING PLATE RH 2 41 ABX 256 PAD, BEARING PLATE LH 2 42 ABX 257 BEARING 19MM X 37MM X 9MM 43 ABX 258 SHIM WASHER 2 44 ABX 259 FTG, ELBOW P4M X PL5F 45 ELBOW 45 ABX 260 FTG, P4M X PL8MMF 90 ELBOW 46 ABX 261 FTG, PL8MMF TO P4M STRAIGHT ADAPTER 47 ABX 262 FTG PL8MMM X PL8MMF 90 ELBOW 48 ABX 263 FTG, PL8MMF TO P4M BSPT STRAIGHT ADAPTER

28 PARTS DIAGRAM AUTOBOX (ABX-2L-V2) HOSE TRACTOR CONTINUED... NOTE: DRIVE ROLLERS, MANIFOLD, AND SHAFT ASSEMBLIES ARE DETAILED ON THE NEXT PAGE # PART NUMBER QTY. 49 ABX 265 AIR MANIFOLD 1 50 ABX 266 FILTER,.25 NPT 2 51 ABX 267 RETAINING RING, SL EXTERNAL SS 52 ABX 268-BK-1 BLACK TUBE 8MM AIR MOTOR FWD 53 ABX 268-BK-2 BLACK TUBE 8MM AIR MOTOR FWD 54 ABX 268-R-1 RED TUBE 8MM AIR MOTOR REV 55 ABX 268-R-2 RED TUBE 8MM AIR MOTOR REV 56 ABX 270-B-1 CLAMP TUBE.25 OD 1 57 ABX 272 DRIVE ROLLER, 70A SMALL HOSE 58 ABX 280 DRIVE ALUMINUM SPROCKET 26T X ABX 281 IDLER ALUMINUM SPROCKET 26T X ABX 283 PLATE, SPACER 1 61 ABX 285 FTG, ELBOW 90 P4M X J4 SS ABX 286 FTG, ELBOW 90 P4M X J8 SS 2 63 ABX 290 REAR MOUNT INSIDE ASSEMBLY 64 ABX MOUNTING BRACKET 2 65 ABX 298 QUICK PIN 17-4 SS.38 X ABX 566 SPRING PLUNGER, PULL RING LOCKING 67 BR DUST CAP 2 68 BR DUST CAP, J BRLM 191 SPRING PIN,.125 X CB 558 FTG, ELBOW P4PL GB BOLT, HEX X.50 SS 2 72 GB BOLT, HEX X.75 SS 2 73 GB BOLT, HEX X 1.50 SS 1 74 GB BOLT, HEX X 1.75 SS 1 75 GK SE-SS KEY 6 76 GK SE-SS KEY 6 77 GN 337-L NYLOK NUT SS 1 78 GN 350-H-20 HEX NUT SS 1 79 GP 013-B BLUE ID BAND, SM GP 013-BK BLACK ID BAND, SM 1 81 GP 013-R RED ID BAND, SM 1 82 GS SHCS X 2.25 SS 2 83 GS SHCS X 1.25 SS 4 84 GS SHCS X.75 SS (TB 050) 85 GS SHCS X 0.88 SS 4 86 GS SHCS X 2.25 SS 6 87 GSB BHCS 6-32 X.188 LG SS 8 88 GSF FHCS X.50 LG SS 8 89 GSF FHCS X.63 LG SS 4 90 GSF FHCS X.50 LG SS 8 91 GSF FHCS X.63 LG SS GSF 3M FHCS M6X1.00X16 SS 1 93 GSF 3M FHCS M6X1.00X20 SS 4 94 GSSH SS SHOULDER SCREW 4 95 GW 337-F FLAT WASHER SS 1 96 HRS 563 FITTING P2 X.25 OD NYLON PUSH

29 PARTS DIAGRAM AUTOBOX (ABX-2L-V2) HOSE TRACTOR SUB ASSEMBLIES NOTE: PART NUMBERS, DESCRIPTIONS, AND QUANTITIES ARE LOCATED ON THE PREVIOUS TWO PAGES 3X UPPER DRIVE ROLLER ASSEMBLY ABX 271 (DARK GRAY/BLACK) ROLLERS ARE INCLUDED IN THE AUTOBOX (ABX-2L-V2) EPP-001 EXTRA PARTS PACKAGE ABX 273 (BLUE ROLLERS) ARE INCLUDED IN THE AUTOBOX (ABX-2L-V2) EPP-001 EXTRA PARTS PACKAGE 3X LOWER DRIVE ROLLER ASSEMBLY MANIFOLD ASSEMBLY

30 PARTS DIAGRAM AUTOBOX (ABX-201) HOSE GUIDE ASSEMBLY MAIN ASSEMBLY PARTS GUIDE NOTE: 1. BLUE GOOP IS A SWAGELOK BRAND ANTI-SEIZE. AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE. 2. BLUE LOCTITE 242 OR EQUIVALENT. 3. COLLET AND GUIDE TUBE SIZES WILL NEED TO BE CHOSEN AND PURCHASED SEPARATELY BY THE CUSTOMER AT TIME OF ORDER. # PART NUMBER QTY 1 ABX QUICK-RELEASE PIN,.250DIA, 3.00L, WITH 6 LANYARD 1 2 ABX 182 SPRING, COMPRESSION 4 3 ABX 183 SCREW, SET, EXTENDED POINT 2 4 ABX 184 BOX SECTION, 2L, HIGH-VISIBILITY 1 5 ABX 185 GUIDE MOUNTING BLOCK, CLAMPING, 2L 1 6 ABX 186 REAR CLAMP CHANNEL, 2L 1 7 ABX 187 PITCH CLAMP PLATE, 2L 1 8 ABX 188 PITCH CLAMP CHANNEL, 2L 1 9 GSB SCREW, BHSC, #10-24 UNC X 0.500L 1 10 GSB SCREW, BHSC, UNC X 0.625L 9 11 GW 325-F WASHER, FLAT, 1/4, STAINLESS 2 12 SRT 557 ADJUSTABLE HANDLE X

31 PARTS DIAGRAM AUTOBOX ABX-2L HOSE GUIDE ASSEMBLY ACCESSORIES GUIDE TUBES, COLLETS, ANTI-TWIST CLAMPS AND HOSE STOPS ABX GUIDE TUBES ABX 11X-XX StoneAge (SA) PART NUMBER GUIDE TUBE REFERENCE CHART GUIDE TUBE BANSHEE INSIDE DIAMETER, LENGTH QTY ABX BN in / 12 mm, 12.5 in. / 318 mm 2 ABX BN in / 12 mm, 36 in. / 914 mm 2 ABX BN in / 14 mm, 12.5 in. / 318 mm 2 ABX BN in / 14 mm, 36 in. / 914 mm 2 ABX BN in / 17 mm, 12.5 in. / 318 mm 2 ABX BN in / 17 mm, 36 in. / 914 mm 2 ABX BN in / 19 mm, 12.5 in. / 318 mm 2 ABX BN in / 19 mm, 36 in. / 914 mm 2 HOSE STOP COLLETS ABX 121-XX StoneAge (SA) PART NUMBER COLLET REFERENCE CHART PART NUMBER DESCRIPTION QTY ABX HOSE STOP COLLET.297 in. / 8 mm 1 ABX HOSE STOP COLLET.328 in. / 8 mm 1 ABX HOSE STOP COLLET.406 in. / 10 mm 1 ABX HOSE STOP COLLET.438 in. / 11 mm 1 ABX HOSE STOP COLLET.460 in. / 12 mm 1 ABX HOSE STOP COLLET.484 in. / 12 mm 1 ABX HOSE STOP COLLET.516 in. / 13 mm 1 ABX HOSE STOP COLLET.547in. / 14 mm 1 ABX HOSE STOP COLLET.594 in. / 15 mm 1 ABX HOSE STOP COLLET.625 in. / 16 mm 1 GUIDE TUBE ANTI-TWIST CLAMPS ABX 140-XX StoneAge (SA) PART NUMBER ANTI-TWIST CLAMP REFERENCE CHART PART NUMBER DESCRIPTION QTY ABX GUIDE TUBE ANIT-TWIST CLAMP ABX GUIDE TUBE ANIT-TWIST CLAMP ABX GUIDE TUBE ANIT-TWIST CLAMP HOSE STOP CLAMPS HS 121-XX-XX StoneAge (SA) PART NUMBER HOSE STOP REFERENCE CHART PART NUMBER DESCRIPTION QTY HS HOSE STOP CLAMP ASSEMBLY, HS HOSE STOP CLAMP ASSEMBLY, HS HOSE STOP CLAMP ASSEMBLY, HS HOSE STOP CLAMP ASSEMBLY, HS HOSE STOP CLAMP ASSEMBLY,

32 PARTS DIAGRAM ABX 290 REAR MOUNT ASSEMBLY NOTE: 1. GREASE O-RING ID AND OD DURING ASSEMBLY. # PART NUMBER QTY 1 ABX HOSE GUIDE PLATE, OUTER 1 2 ABX 230 SPIRAL INTERNAL RETAINING RING,.625 BORE, SS 4 3 ABX REAR MOUNTING BRACKET, INSIDE 1 4 ABX 293 SPACER, ORING 12 5 ABX 294 ORING, SHOCK ABSORBER 10 6 GSF FHCS X.63 Lg SS

33 PARTS DIAGRAM LIGHTWEIGHT POSITIONER ASSEMBLY (LWP-500-XX-V2) NOT INCLUDED IN PACKAGE # PART NUMBER QTY 1 BR 002-XX BOX RAIL EXTRUSION 1 2 BU 002-XX BOX RAIL EXTRUSION, SLOTTED 2 3 LWP LIGHTWEIGHT POSITIONER PARTS

34 PARTS DIAGRAM AUTOBOX (CB-ABX) CONTROL BOX NOTES: 1. ASSEMBLY REFERENCE DIMENSION SHOWN (MM) / INCHES. # PART NUMBER QTY. 1 CB 300 CONTROL BOX ASSEMBLY 1 2 CB 301 CB STAND ASSEMBLY 1 3 CB 310 FRL ASSEMBLY 1 4 CB ABX HOSE BUNDLE ASSEMBLY

35 PARTS DIAGRAM AUTOBOX (CB 300) CONTROL BOX ASSEMBLY (CONTINUED ON NEXT PAGE) # PART NUMBER QTY. 1 BR 167 DUST CAP 1 5 CB 321 CB FRAME 1 6 CB 322 SIDE PLATE 2 7 CB 323 BRACE REAR 2 8 CB 324 BRACE FRONT 2 19 CB 355 FTG P8J8 BRASS MALE TO MALE 1 25 GPTB 0375-PUR95A-BL 8FT 28 GTB BHTS X.50 LG TORX-SS

36 PARTS DIAGRAM AUTOBOX (CB 300) CONTROL BOX ASSEMBLY (CONTINUED) FRONT ASSEMBLY TOP ASSEMBLY REAR ASSEMBLY TOP ASSEMBLY # PART NUMBER QTY. 1 BR 167 DUST CAP 1 2 CB CE SERIAL PLATE 1 3 CB LOBE KNOB 1 4 CB 320 GRAPHIC OVERLAY 1 9 CB 325 HANDLE TOP 2 10 CB 326 HANDLE FRONT 1 11 CB COUPLER PLATE, REAR ASSEMBLY 12 CB POLE MOUNT CB 333-HD PNEUM3WAYASSY 3 14 CB 334 RY3 AAA PILOTED SPOOL VALVE ASSY 15 CB 335 REG ASSY 1 16 CB 337-HD PNEUM3WAYASSY - DUMP 1 17 CB 347 CAP PLATE 1 18 CB 349 FTG P4F PL6 STRAIGHT 1 19 CB 355 FTG P8J8 BRASS MALE TO MALE 20 CB 548-SS GAUGE 1 21 GSB BHCS 6-32 X.50 LG SS GB BOLT, HEX X.75 SS 4 23 GN 319-L NYLOK NUT SS (HC 025.1) 4 24 GPH PHPMS X 2.00 SS 4 26 GR 125-SS RIVET 4 27 GSB 3M BHCS M8X1.25 X 16 SS 28 GTB BHTS X.50 LG TORX-SS 29 GTB BHTS X.63 LG TORX-SS 30 GW 337-F FLAT WASHER SS

37 PARTS DIAGRAM AUTOBOX (CB ) COUPLER PLATE, REAR ASSEMBLY NOTES: 1. INSTALL ALL PUSH LOCK FITTINGS TO THE BACK SIDE. 2. INSTALL ALL JIC FITTINGS TO THE FRONT SIDE. 3. ASSURE THREAD TAPE OR PIPE DOPE IS USED ON ALL FITTINGS 4. INSTALL ALL GP 011 BANDS OVER COUPLER AND AGAINST FACE OF PLATE. # PART NUMBER QTY. 1 BR 167 DUST CAP 2 2 BR 168 DUST CAP, J4 5 3 CB COUPLER PLATE, REAR WELDMENT 1 4 CB 330 P8PL6 4-WAY MANIFOLD 1 5 CB 339 P4P6 MANIFOLD 2-WAY 1 6 CB 343 FTG P8P4 BUSHING 1 7 CB 346 FTG P8 T-FITTING 1 8 CB 351 FTG P4PL6 SWIVEL ELBOW 6 9 CB 354 FTG P4PL6 STRAIGHT 2 10 CB 356 FTG P4J4 BRASS MALE TO MALE 5 11 CB 357 FTG P4J8 BRASS MALE TO MALE 2 12 CB 365 FTG P4P4 ELBOW 1 13 CB 704 PRESSURE REGULATOR, 60 PSI 1 14 GP 011-B BLUE ID BAND MED 1 15 GP 011-BK BLACK ID BAND MED 1 16 GP 011-R RED ID BAND MED 1 17 SM 309 FITTING, BUSHING P4M PL

38 PARTS DIAGRAM AUTOBOX (CB 301) CB STAND ASSEMBLY # PART NUMBER QTY. 1 CB CUSTOM SUMNER STAND 1 2 CB 303 MTG POLE 1 3 CB LOBE KNOB 1 4 PL 163 DECAL, LEG TOWARD OPERATOR 1 AUTOBOX (CB ) CONTROL LINE ASSEMBLY # PART NUMBER QTY. UNITS 1 GP 053 1/2 PUSH-ON BRASS HOSE FITTING 1/2 JIC 4 2 GPHO 0250-RUB-RD 1/4 ID X 1/2 OD PUSH-ON AIR HOSE, BUNA-N/PVC, 250 PSI, RED GPHO 0500-RUB-BK 1/2 ID X 3/4 OD PUSH-ON AIR HOSE, BUNA-N/PVC, 250 PSI, BLACK GPHO 0500-RUB-RD 1/2 ID X 3/4 OD PUSH-ON AIR HOSE, BUNA-N/PVC, 250 PSI, RED GPHS 2000-OLE-A-BK 2.00 DIA HEAVY DUTY MOISTURE SEAL HEAT-SHRINK GPSL 1750-NYL-G-BK 1.75 DIA BRAIDED EXPANDABLE HEAVY DUTY NYLON SRT 122 1/4 PUSH-ON BRASS HOSE FITTING 1/4 JIC

39 PARTS DIAGRAM AUTOBOX (CB 310) FRL ASSEMBLY SEE NEXT PAGE FOR CB 312 PARTS LIST NOTES: 1. CLEAN ALL DEBRIS & OILS BEFORE INSTALLING. INSTALL AT APPROXIMATE ORIENTATION AND LOCATION & AT ROOM TEMP. 2. APPLY BLUE LOCTITE (PN: 242 OR EQUIVALENT) TO ALL STRAIGHT THREADED FASTENERS. 3. APPLY THREAD SEALANT (LOCTITE 567 OR EQUIVALENT) TO ALL TAPERED THREADS. 4. ADD BLUE GOOP WHICH IS A SWAGELOK BRAN ANTI-SEIZE TO ALL OTHER THREADED HARDWARE OR AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE. # PART NUMBER QTY. 1 CB HOSE ASSY (FOR CB ABX) 1 2 CB 114 INLET FITTING 1 3 CB 311 FRL FRAME 1 4 CB 312 GEN3 FILTER-REGULATOR-LUBRICATOR WITH GEN2 CLAMP 1 5 CB 313 ROD 2 6 CB LOBE KNOB 1 7 CB POLE MOUNT 1 8 CB 395 FRL BRACKET 1 9 CB 792 VALVE, AUTODRAIN, P CB 793 BREATHER, SINTERED BRONZE, P GB BOLT, HEX X.75 SS 2 12 GN 331-L NYLOK NUT SS 2 13 GSB BHCS X.88 LG SS 4 14 GTB BHTS X.50 LG TORX-SS 4 15 GW 331-F FLAT WASHER SS 2 16 GW 337-F FLAT WASHER SS 2 17 HRS 573 FITTING 90 DEG P8J ML 077-P8 BUSHING 1 19 PL CAUTION INLET AIR, 125PSI MAX 1 20 SBT FTG 90 ELBOW P8MP8M

40 PARTS DIAGRAM AUTOBOX (CB 312) GEN 3 FILTER, REGULATOR, LUBRICATOR WITH GEN 2 CLAMP # PART NUMBER QTY. 1 CB FILTER REGULATOR ASSEMBLY 1 2 CB FILTER REGULATOR BOWL 1 3 CB FILTER 1 4 CB GAUGE WITH LENS 1 5 CB ORING 2 6 CB LUBRICATOR ASSEMBLY 1 7 CB LUBRICATOR BOWL 1 8 CB SPACER W BRACKET

41 ABX-2L ACCESSORIES 1 LWP-500 POSITIONER With its multiple mounting options, the LWP-100 positioner can adapt to almost any heat exchanger. Two high-powered pneumatic motors provide fast, precise positioning. Entire unit can be set up and operated with a single operator and minimal hand tools. Anodized aluminum rails provide maximum chemical and corrosion resistance. 2 AST-200 AUTOSTROKE AUTOMATIC BLOCKAGE SENSOR Maximizes head life and cleaning efficiency by automatically detecting blockages and methodically working through the obstruction Easily installs in-line to your pneumatic lines. The perfect complement to your ABX-2L system. HEAD CONTACTS BLOCKAGE AND STOPS ROTATING AUTOSTROKE 'SENSES' BLOCKAGE AND PULLS HOSE BACK SIGHTLY TO REGAIN HEAD ROTATION HEAD REGAINS NORMAL ROTATION AND HOSE FEED CONTINUES 3 HCS-2L HOSE CONTAINMENT Holds up to 100 ft (30 m) of hose. Built-in backout prevention for improved job site safety. Keeps job site clear of trip hazards. Helps manage hoses for easy transport and storage. Greatly extends hose life. 4 FIN-FAN ATTACHMENT Allows the ABX-2L to be operated in confined walkways to access Fin-Fan exchangers. Adjustable pitch. Customized lengths available. Scaffold attachment available